How it Works
Simplex
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Saturn 3000
Series Manual
54 pgs2.1 Mb0

Simplex Saturn, Saturn 1400, Saturn 1600, Saturn 1800, Saturn 1700 Series Manual

...
SATURN
1400KW3200KW
STATIONARY LOAD BANK
Last Revision Date: March 15, 2016
For the most up-to-date information for this product and others, please
contact Simplex, Inc. at (800) 637-8603 or visit us on the web at
http://www.simplexdirect.com.
Table of Contents
Safety information symbols 1 Cautions 1
Overview of Use 4 Control System 4 Cooling System 4 Load System 4 Safety 4
Included Components 6 Primary Inspection 6
Load Bank Placement 7 Installation Procedure 8 Remote HMI installation 9 Load Dump installation 10 Current Transformer installation 11 MODBUS installation 13 Heater installation 14 BMS/BAS Installation 15
General Settings 16 Automatic Mode 16
Pre-operation checks 17 Setting up the test 17 Testing operation 18 Metering (if equipped) 18 Shutdown and cooling 18
Overview 19 Setting Up Automatic Mode 20 Entering Automatic Mode 20
General maintenance 21 Each Operation 21 Every 6 Months 21 Troubleshooting 22
Alarms 23 Warnings 23
APPENDIX A  PARTS LISTINGS ...........................................................25
APPENDIX B  MODBUS CONTROLS ...................................................41
Modbus Control Directions 44
APPENDIX C  PRODUCT WARRANTY .................................................45
Table of Figures
Current draw at specic resolutions (in kilowatts) ...............................5
Air Flow ................................................................................................................7
Ground Bus ......................................................................................................... 8
Main Load Bus ...................................................................................................8
Conduit Opening .............................................................................................. 8
HMI TBH................................................................................................................9
Serial Adapter ....................................................................................................9
TB-DC .................................................................................................................... 9
Load Dump Jumper ...................................................................................... 10
Current Transformers ................................................................................... 11
CT Orientation ................................................................................................ 11
TB-CT .................................................................................................................. 11
Current Transformer placement for Metering ..................................... 12
Current Transformer placement for Auto/Regen. Mode ................. 12
TB-COM ............................................................................................................. 13
Modbus Serial Converter ............................................................................ 13
TB-SH .................................................................................................................. 14
TBR ...................................................................................................................... 15
Setup Screen ................................................................................................... 16
General Settings............................................................................................. 16
HMI Information ............................................................................................. 18
Alarm History .................................................................................................. 18
Automatic/Regenerative Mode ................................................................ 19
Setup Screen ................................................................................................... 19
Automatic Mode Setup ............................................................................... 19
Automatic Mode Running .......................................................................... 20
Troubleshooting ............................................................................................ 22
Troubleshooting alarms .............................................................................. 24
Right Subpanel Layout ................................................................................ 25
Option D - Automation/Metering............................................................ 26
Option B - Communication (TCP/IP Data Logging) ........................... 27
PLC Component list ...................................................................................... 28
Control Relays ................................................................................................. 30
Terminal Blocks ............................................................................................... 32
Option 010 - Space Heaters ....................................................................... 34
Center Subpanel ............................................................................................ 36
Phase A Detail ................................................................................................. 37
Phase B Detail ................................................................................................. 38
Phase C Detail ................................................................................................. 39
Load Control Terminal Blocks ................................................................... 40
Modbus Controls (Read/Write) ................................................................. 41
Modbus Indications (Read only) .............................................................. 42
1 WARNINGS AND CAUTIONS
Safety
information
SymbolS
CautionS
e following images indicate important safety information:
is General warning symbol points out important information that, if not followed, could endanger personal safety and/or property.
is Explosion warning symbol points out potential explosion hazards.
is Fire warning symbol points out potential re hazards.
is Electrical warning symbol points out potential electrical shock hazards.
is load bank is high-powered, technical, industrial equipment operating at dangerous voltages and temperatures. It is capable of damaging itself, property or personnel if improperly used. It is not a consumer product.
It must be installed, connected and operated by personnel properly trained and experienced in its use. An operator’s manual is supplied with each load bank and available online at www.simplexdirect.com. e operator must be familiar with its contents and have access to it during operation.
• High Voltage: Turn o and disconnect power source before
opening this equipment
• High Temperature: Allow hardware to cool before servicing
or opening this equipment.
• Rotating Equipment: Ensure that the fans have stopped
before opening this unit.
• For Operator Safety: Make sure this equipment is properly
grounded when in use.
All compression-type connections on fuse blocks, load blocks, and contactors should be checked for tightness frequently. is check should be established as part of routine maintenance.
e following cautions should be observed before and during operation:
• Check intake and exhaust screens as well as fan and load
elements for foreign objects.
• Position and install the load bank with consideration given
Warnings and Cauons — 1
to large cubic airow requirements, exhaust temperature, and velocity. Do not point exhaust at any nearby surface or object that may be adversely aected by high temperature. is includes but is not limited to painted surfaces, tar paper and asphalt roofs, water sprinkler heads, re alarms, and volatile material.
• Do not use in conned spaces. Do not allow the load bank’s feet to sink into so surfaces thereby cutting o bottom air intake. e load bank may have to compete with cooling air requirements of a nearby running engine generator set where cooling air intake to a conned space may not be adequate for both engine and load bank. Be especially careful not to bounce hot exhaust air o nearby obstructions for re­circulation through the load bank.
• Verify that all control switch positions are set correctly for your intended usage before connecting the load bank to the source to be tested.
• e load cables carry high amperage. Be constantly aware of possibility of inductively heating adjacent ferrous objects to temperatures sucient to damage cable insulation.
• Always connect the safety ground cable to a proper ground. Do not rely on a possible grounded neutral somewhere else in the system.
• Do not let the load bank run unattended for long periods of time.
• Do not store or operate in rain unless adequate protection is provided.
• Routinely inspect all components and electrical connections for tightness and integrity.
• Repair any damaged or degraded components and wiring without delay.
• If technical assistance, service, or parts are needed, please call 800-837-8603 (24 Hours).
• All hardware covered by this manual have dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc. Ensure all appropriate covers, guards, grounds, and barriers are in place before operating the equipment. If work must be done around an operating unit, stand on an insulated dry surface to reduce the risk of electrocution.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while your hands or feet are wet.
• If people must stand on metal or concrete while installing, servicing, adjusting, or repairing this equipment, place insulative mats over a dry wooden platform. Work on the
2 — Warnings and Cauons
equipment only while standing on such insulative mats.
• e National Electrical Code (NEC), Article 250 requires the frame to be connected to an approved earth ground and/or grounding rods. is grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition or by static electricity. Never disconnect the ground wire while the load bank is in use.
• Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment, ensure that all power voltage supplies are completely turned o at their source. Failure to do so can result in hazardous and possibly fatal electrical shock.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply rst aid and seek immediate medical attention.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury.
• Keep a re extinguisher near the hardware at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to re extinguishers, please consult the local re department.
• e illustrations in this manual are examples only and may dier from your load bank.
• Load Bank warranty is void if incorrectly cooled.
Warnings and Cauons — 3
2 DESCRIPTION AND SPECIFICATION
overview of
u
Se
Control
S
yStem
Cooling
S
yStem
Simplex Saturn load banks are precision test instruments designed to apply a selectable load to a power source and measure the source’s response. ey are used for routine maintenance exercise to ensure the long-term reliability and readiness of the standby generator. Load banks can also eliminate the detrimental eects of unloaded operation of diesel engine generators as well as prevent damage from reverse power generation.
Saturn load banks are available in models ranging from 1400 kilowatts up to 3200 kilowatts. All standard Saturn models have a step resolution of 25 kilowatts.
Saturn load banks feature a Human-Machine Interface (HMI) touchscreen, which controls load bank operation and displays the unit’s status. With the HMI, the operator can apply a desired load and measure the response of the test source.
e load bank can also be integrated into your facility’s BMS/ BAS system via standard Modbus RS-485 or optional Modbus TCP/IP, as well as a set of dry contacts for status reporting.
Saturn load banks are cooled by forced air, delivered by an aluminum fan blade directly driven by a TEFC motor. e air is brought in on the bottom of the load bank and expelled through the top. Optional equipment allows the exhaust to be driven through a customer-installed duct, providing for indoor installation.
load SyStem
Safety
4 — Descripon and Specicaon
e load system comprises independently controlled Simplex Powr-Web resistors, which have been designed specically for use in load bank systems. e load elements are supported by high-temperature, ceramic-clad, stainless-steel rods across their entire length, virtually eliminating element-to-element short circuits. e elements are arrayed in discrete trays, which are independently serviceable.
e Saturn is protected by sensors to ensure that the load bank is suciently cooled and that the exhaust does not exceed a safe temperature, which could damage the load bank or present a safety hazard to the operator. When a failure occurs, the safety system immediately removes the load to protect the equipment from permanent damage.
1400 1500 1600 1700
416V
480V
600V
416V
480V
600V
416V
480V
600V
416V
1943A 2082A 2221A 2359A
1684A 1804A 1925A 2045A
1347A 1443A 1540A 1636A
1800 1900 2000 2100 2200
2498A 2637A 2776A 2915A 3053A
2165A 2285A 2406A 2526A 2646A
1732A 1828A 1925A 2021A 2117A
2300 2400 2500 2600 2700
3192A 3331A 3470A 3608A 3747A
2766A 2887A 3007A 3127A 3248A
2213A 2309A 2406A 2502A 2598A
2800 2900 3000 3100 3200
N/A N/A N/A N/A N/A
480V
600V
ese measurements are based on ideal numbers. ey do not take into account control power draw, power cable resistance, voltage droop, etc.
3368A 3488A 3608A 3729A 3849A
2694A 2791A 2887A 2983A 3079A
Descripon and Specicaon — 5
3 UNPACKING
.
inCluded
C
omponentS
primary
i
nSpeCtion
If any
problems
are observed
during
Primary
Inspection,
call Simplex
24 hours a
day at
800-637-8603
e following items are included with your load bank. If any of the following are not included, please contact Simplex Direct at 800-637-8603.
1. Load bank
2. Controller (remote or local)
3. Manual
4. Drawing package
Optional equipment
1. Additional controllers
2. Exhaust hood
3. Current transformers
4. Other optional equipment
Before installing your Saturn, inspect the shipping crate and load bank. Physical or electrical problems could arise from handling and vibration. Never apply power to a load bank before performing this procedure. e following ve-point inspection is recommended before installation and as part of a 6-month maintenance schedule or when the load bank is relocated:
1. If the crate shows any signs of damage, examine the load
bank in the corresponding areas for signs of initial problems.
2. Check the entire outside of the cabinet for any visual damage,
which could cause internal electrical or mechanical problems
due to reduced clearance.
3. Open the control panel door and inspect all relays and
control modules. Make sure all components are secure in
their bases and safety bails are in place. Spot-check electrical
connections for tightness. If any loose connections are found,
inspect and tighten all remaining connections.
4. Examine all accessible internal electrical components such
as fuses, contactors, and relays. Check lugged wires at these
components.
5. Check the load element chamber for foreign objects, broken
ceramic insulators, and mechanical damage.
6 — Unpacking
4 INSTALLATION
load bank
p
laCement
Improperly
installing
this unit may
result in
damage or
destruction
of the
load bank,
adjacent
equipment,
and the
building
housing the
unit.
Normally equipped, Saturn load banks are intended for outdoor installation. A forced air system, which discharges out of the top of the unit, cools the load elements (See Figure 1 Air Flow.) Load banks require large quantities of air circulation, so it is essential to install the unit in an area that provides adequate airow. Before conducting load tests, a review of site conditions by trained personnel is recommended.
e load bank requires at least 20 feet of vertical clearance; 6 feet of clearance on the front, le, and right; and 1.5 feet of clearance in the rear (see “Figure 2 Clearance requirements”
on page 11).
e load bank should be placed in a secure area accessible by trained personnel only.
Figure 1 Air Flow
Because the unit generates a lot of heat, never operate near sprinkler systems.
Operating the load bank in a conned space will recycle hot exhaust air through the cooling system, which can cause severe damage.
e load bank may compete with nearby generators for cooling air.
Installaon — 7
inStallation
p
roCedure
Saturn load
banks feature
a power
outlet in the
control panel
for your use.
This outlet is
limited to 2
amps.
1. To bring in the source’s power cables, pull holes in the Conduit Opening, located in the bottom of the load bank’s control panel enclosure (see
Figure 5 Conduit Opening).
2. Conrm the test source is properly grounded.
3. Ground the load bank by connecting the Grounding Bus to an earth ground or grounding rod. See Figure 3 Ground Bus
4. Connect the source’s power output to the load bank via the Main Load Bus with appropriately sized cables (see Figure 4
Main Load Bus).
Figure 2 Ground Bus
Figure 3 Main Load Bus
8 — Installaon
Figure 4 Conduit Opening
remote Hmi
inStallation
If your HMI is installed directly on the load bank, skip to the next section.
1. Mount the HMI where
desired.
2. Connect the HMI to the
Load Bank by swinging
the HMI’s screen out to
expose the TB-H terminal
block (see Figure 6 HMI
TBH) and wiring it to the
Load Bank.
A. Using a Belden 9841
or equivalent cable, make the following connections between the HMI’s TB-H terminals to the Serial Adapter (see Figure 7
Serial Adapter).
1. TB-H 4 → TXD+
2. TB-H 5 → TXD-
3. Wire shielding → COM B
Figure 5 HMI TBH
Figure 6 Serial Adapter
B. Using a copper wire,
14AWG or larger, rated at 60C or higher, connect the HMI’s TBH 1 to the load bank’s TB-DC 1 terminal and the HMI’s TBH 2 to the load bank’s TB-DC 3 terminal (see Figure 8
TB-DC).
Figure 7 TB-DC
Installaon — 9
load dump
inStallation
If the Load Dump feature is desired, remove the factory-installed jumper at TB-R 1–2 and connect customer-supplied Load Dump contacts to TB-R 1–2 (See Figure 9
Load Dump Jumper). To
dump the load, open the customer-supplied contact. To enable load, close the customer-supplied contact.
Load Dump Jumper
Figure 8
10 — Installaon
Current
t
ranSformer
inStallation
The current
transformers
must be
placed and
oriented correctly to ensure they
accurately
detect the
current. The
rst current
transformer
must be
installed on
Phase A, and
the second
must be
installed on
Phase C.
If your load bank is equipped with Metering, Automatic Mode or Regenerative Mode options, you will have to install current transformers on your power cable.
• For metering mode,
install the current
transformers on the load
bank leg of your power
system (see “Figure 13
Current Transformer
placement for Metering”
on page 12.)
• For Automatic/
Regenerative Mode,
install the current
transformers on the power
source leg (see “Figure 14
Current Transformer
placement for Auto/
Regen. Mode” on page
12.)
Orient the current transformers so that the XI or HI on each ring is facing the power source (see Figure 11
CT Orientation.)
When the current transformers are installed, connect them to the load bank by connecting the white wire of the current transformer on Phase A to TB-CT 1 and the black wire to TB-CT 2. If a second current transformer is installed on Phase C, connect its white wire to TB-CT 3 and its black wire to TB-CT 4 (see Figure 12 TB-CT.)
Make sure the XI or HI on the ring faces the power source.
Figure 9
Current Transformers
Figure 10
CT Orientation
Figure 11 TB-CT
Installaon — 11
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